High molecular weight linear polycarbonates



3,052,780 Patented Nov. 6, 1962 3,062,780 HIGH MQLECULAR WEIGHT LINEAR PGLYCARBONATES Heinrich Rinke, Leverkusen-Saar, Wolfgang Lehmann,

and

Levfirkusen'Bayerwerk f Herman lk R and R being selected from the group consisting of 2 :2 :3 g g gggg iii ggggzg gi:::$; 3 g: hydrogen, unbranched and branched monovalent aliphatic mm ofgGe'rmany hydrocarbon residues up to 10 carbon atoms, monovalent N0 Drawing Filed N0 20, 1957 Sen 697532 cycloahphatic residues, monovalent araliphatic hydrocar- Claims Priority li fi Germany 0 19 bon resldues having up to 4 carbon atoms as side-chains, 21 Claims. (Cl. 260-47) 10 the phenyl and the furyl residue Z represent ng the car- This invention relates to high molecular linear poly hon and hydrogen atgms completing a cycloahphagc and each nucleus ein substituted with 1-4 alogen carbonates containing recurring groups having the followatoms g mg genfiral formula: 'These polycarbonates are distinguished by the sum of some remarkable properties which is not known on other 0 comparable high molecular weight linear polycarbonates l1 known in the art such as the corresponding polycarbouates which are not halogen-substituted at the nuclei or polycarbonates of non-hydroxyalkylated aromatic dihy-' 1 l e t i ii e ifr c iup c ii s t i g 3? 13 153: ifi i iaiogiiiii ai i 2O drOXY Compounds, pecially of 4,4'-dihydroxyrepresents an aromatic nucleus which is connected to the alkan-es halogena-ted as wel-l as non-halogenated at yg atoms in the above general formula y p link llllclil. Such spec1a1 piopertlreslof the rllew polycarbonates are or instance: a re ative y ow met viscosity in con- 2165 directly attached to an aromatic nucleus and which a is selected from the roup consistin of the following 25 necnon with pamcularly good solublht-y m great 1 number of usual solvents, an extremely high resistance Ia lca to hydrolysis by acids and especially by aqueous bases, an extremely low water absorption, a high resistance to air at elevated temperatures, an extremely low tendency to crystallization and a high resistance to inflammability. O-SOQ The following table compares the corresponding values of some typical representatives of polycarbonates.

Polycarbonate of 2,2- Polycarbonate of 2,2- Polycarbonate of 2,2- Polycarbonate of 2,2- 4,4-dihydroxy- (4,4'-dihyrlroxy- (4,4-dihydroxyttly r xy- 3,5,3,5-l( tra-chl0r0- diphenylc-nel-pro- 3,5,3,5tetrachlorodiphcnylene)-propanc diphenylene)propane pane-bis-(fl-oxyethy1- diphen vlene)-proether) pane-bis-(fi-oxyethyL ether) gilscgsitty oi the melt (K-value 52 at 280 0.)- about 30,000 poises 50,000 [noises 10,000 poises 10,000 poises.

0 l1 1 l y 111-- mcthylene chloride chloroform bcnzene toluene (-1-) gggtgilgcid este ((i Softening part1:

about 220C about 250 0 120130 o 170-190" 0. Second order transition point 140-150 C about 180 C about C 8090 C. Saponifiability of a foiitwith run thirlzksaponi[yingnumber=28. saponityingnumber=6 saponifyingnumbcr=0 ness 11'] aqueous 03115 10 potassium S0 11- tion by boiling for 2 hours. Water absorption in 95 percent relative 0.16 0.18. 0.13.. 0.03.

humidity content. In percent relative humidity content 0.09. 0.09.- 0.05.. 0.01. Discoloration after heating for 1 hour in air 2-'% 3-4 2 2.

at 200 0. (discoloration number of the starting material=1). lnfiammability mflammable non-inflammable inflammable non-inflammable.

++=very well soluble, +=well soluble, =poor1y soluble, =very poorly soluble, -=insolub1e.

The sum of the properties of the new polycarbonates, particularly the low tendency for crystallization and the good solubility in a great number of solvents, makes these plastics suitable especially for manufacturing moulded articles by injection moulding and for coatings respectively, particularly when non-inflammability is desired.

The new polycarbonates may be produced by polyinterestifying the corresponding dihydroxy compounds with dialkylor diaryl esters of carbonic acid, e.g. dimethyl-, diethyl-, dipropyl-, dibutyl, diamyl-, dioctyl-, dicyclohexyl-, and especially with the diphenyland diomor ptoluyl carbonic acid ester, or with mixed esters, for instance with the methyl-ethyl, the methylpropyl, the ethyl-propyl, the methyl-cyclohexyl, the ethylcyclohexyl, the propyl-cyclohexyl, the methyl-phenyl, the

ethyl-phenyl, the propyl-phenyl, the ethyl-o-, m-' or p-toluyl and the cyclohexyl phenyl carbonate, that is by heating mixtures of the dihydroxy compounds and the carbonic acid esters in about equimolecular ratios at temperatures from about 120 to about 300 C. and especially from about 170 to about 270 C. preferably under reduced pressure while splitting off the corresponding monohydric alcohol or phenol respectively until a viscous filrnand fibre-forming melt is obtained.

Instead of mixtures of the corresponding dihydroxy compounds and dialkylor diaryl esters of carbonic acid mentioned above there may also be heated bis-alkyl-, cycloalkylor aryl esters of the corresponding dihydroxy compounds alone or in mixture with free dihydroxy compounds. In the first case neutral dialkyl-, di-cycloalkyl or diaryl carbonate splits off, in the second case the corresponding monohydroxy alkyl-, cycloalkylor aryl compound splits off.

In general inter-esterifying catalysts such as: inorganic bases, for example caustic soda and potassium hydroxide, high boiling organic bases such as acridine, metal hydrides such as lithium and calcium hydride, alkali or alkaline earth metals such as sodium, potassium, magnesium, and calcium, metal oxides such as zinc oxide, aluminium oxide, lead oxide, antimonotrioxide, cerium oxide, and boron oxide, acids such as phosphoric acid and p-toluene sulphonic acid, and salts such as sodium benzoate, calcium acetate, and boron phosphate, and alcoholates and phenolates may be added to the reaction mixture.

When using basic catalysts we prefer to neurtalise the catalyst by adding basic-binding agents to the melt towards the end of the poly-inter-esterification. Suitable basebinding agents are for instance aromatic sulphonic acids such as p-tolyl sulphonic acid, organic acid halides such as stearyl chloride, butyryl chloride, benzoyl chloride, and toluene sulphochloride, organic chlorocarbonates such as phenyl chloroformate, p-hydroxy-diphenyl chloroformate, and bis-chloroformates of di-monohydroxy arylene alkanes, dialkylsulphates such as dimethyl sulphate and dibutyl sulphate, organic chlorine compounds such as benzyl chloride and w-chloroacetophenone as well as acid salts of polycondensation inorganic acids such as ammonium hydrogen sulphate.

Base-binding substances which are volatile under greatly reduced pressure at esterification temperatures are especially suitable since an incidental excess over that required to neurtalise the basic catalysts can be easily removed from the melt. Dimethyl sulphate, phenylchloroformate and benzoyl chloride are examples of substances of this group.

The dihydroxy compounds which may be used for the production of the new polycarbonates are obtainable by reacting the corresponding nucleus-halogenated aromatic dihydroxy compounds with ethylene oxide or propylene oxide by methods well known in the art.

Among the aromatic dihydroxy compounds suitable for the present invention there may be mentioned: halogenated hydroquinone, 4,4-dihydroxydiphenyl, 4,4-dihydroxydiphenylene sulphone, 4,4-dihydroxybenzophenone, and particularly halogenated 4,4'-dihydroxydiphenylene alkanes such as 4,4-dihydroxydiphenylene methane,

1, 1- (4,4 -dihydroxy-diphenylene) -ethane,

1,1-(4,4-dihydroxy-diphenylene) -propane,

1, l (4,4-dihydroxy-diphenylene) -butane,

1,1-(4,4-dihydroxy-diphenylene) -2-methyl-propane,

1, l-(4,4-dihydroxy-diphenylene) -heptane,

1,1-(4,4-dihydroxy-diphenylene) -l-phenyl-methane,

(4,4-dihydroxy-diphenylene) (4-methyl-phenylene) methane,

(4,4'-dihydroxy-diphenylene) (4-ethyl-phenylene) methane,

( 4,4'-dihydroxy-diphenylene) (4-isopropyl-phenylene) methane,

(4,4'-dihydroxy-diphenylene) (4-butyl-phenylene) methane,

(4,4'-dihydroxy-diphenylene) -b enzy -m 65 thalene,

4- 4,4-dihydroxy-dipheny1e rie) -a-furyl-methane, 2,2-(4,4-dihydroxy-diphenylene)-propane, 2,2-(4,4-dihydroxy-diphenylene)-butane, 2,2-(4,4-dihydroxy-diphenylene)-pentane (melting point 149-150" C.), 2,2-(4,4-dihydroxy-diphenylene)-4-methyl-pentane, 2,2-(4,4-dihydroxy-diphenylene)-heptane (boiling point 198200 C. under 0.3 mm. mercury gauge), 2,2-(4,4-dihydroxy-diphenylene)-octane,

l 2,2-(4,4'-dihydroxy-diphenylene)-nonane (melting point 1,1-(4,4 dihydroxy-diphenylene) -1-phenyl-ethane, (4,4'-dihydroxy-diphenylene)-1-( a-furyD-ethane, 3,3-(4,4'-dihydroxy-diphenylene) -pentane,

4,4-(4,4-dihydroxy-diphenylene)-heptane,

1,1-(4,4'-dihydroxy-diphenylene) -cyclopentane,

1,1- 4,4-dihydroxy-diphenylene) -cyclohexane,

furthermore 4,4-dihydroxy-diphenylene oxide,

4,4-dihydroxy-diphenylene sulphide,

1,5-dihydroxy naphthalene, 2,6-dihydroxy naphthalene and 1,4-dihydroxy naphthalene.

As mentioned above the nuclei of these aromatic dihydroxy compounds may be substituted with 1-4 halogen atoms that is with fluorine, chlorine, bromine and iodine. Special halogenated aromatic dihydroxy compounds are for instance Octa-chloro-4,4'-dihydroxy-diphenyl,

Tetra-chloro-4,4-dihydroxy-diphenyl,

Tri-chloro-4,4-dihydroxy-diphenyl,

Di-chloro-4,4'-dihydroxy-diphenylene sulphone (melting point 194-1955 C.),

2,2-(4,4-dihydroxy-3,3-di-chloro-diphenylene)-propane,

2,2 (4,4 dihydroxy 3,5,3',5' tetra chloro diphenyl ene -propane,

2,2 (4,4 dihydroxy 3,5,3',5' tetra bromo diphen ylene)-propane (melting point l76-l80 C.),

40 1,1 4,4 dihydroxy 3,5335 tetra chloro diphenyl- 2,3,5,6-tetra-chloro-hydroquinone,

3,5,3',5' tetra chloro 4,4 dihydroxy diphenylene methane,

2,3,5,6,2,3',5',6' octa chloro 4,4 dihydroxy di phenylene-methane,

3,5,3,5-tetra-chloro-4,4'-dihydroxy-benzophenone,

3,5,3,5-tetra-bromo-4,4'-dihydroxy-benzophenone.

A part of the nucleus halogenated alkoxylated dihyhydroxy compounds mentioned above may be replaced by non-halogenated aliphatic, cycloaliphatic or aromatic dihydroxy compounds such as diethylene glycol, triethylene glycol, polyethylene glycol, thiodiglycol, ethylene dithiodiglycol, the di-, and polyglycols produced from propylene-0xide-l,2, 0-, m-, or p-xylylene glycol, propanediol-l,3, butanediol-1,3, butanediol-l,4, Z-methylpropancdiol-l,3, pentanediol-l,5, 2-ethylpropanediol-l,3, hexanediol-l,6, octanediol-l,8, 1-ethylhexanediol-l,4 and decanedioll,l0, cyclohexanediol-l,4, 2,2-(4,4-di-hydroxy-dicyclohexylene)-propane and 2,6-dihydroxy-decahydronaphhydroquinone, resorcinol, 4,4-dihydroxy-diphenyl, 1,4-dihydroxy-naphthalene, 1,6-dihydroxy-naphthalene, 2,6-dihydroxy-naphthalene, 1,5-dihydroxy-napbthalene, dihydroxy-anthracene, 4,4-dihydroxy-dinaphtl1yl- 1,1, and m-, p-hydroxy-benzylalcohol and particularly 4,4-dihydroxy-diphenylene alkanes, sulphones, oxides and sulphides mentioned above, but non-halogenated. In general however, the mixtures should be composed in such a manner that the halogen content of the end product is up to about 10 percent and particularly between about 5 to about 40 percent by weight.

Example 1 A mixture of 0.1 mol of 2,3,5,6-tetra-chloro-hydroquinone-bis-(,B-hydroxyethyl ether)=33.6 parts by weight and 0.1006 mol of diphenyl carbonate=21.52 parts by weight is heated under stirring and passing through purilied nitrogen during 2 hours at 200 C. Then the temperature is increased to 230 C. during a further hour and the heating at that temperature is continued for 3 hours. After slowly increasing the temperature to 250 C. the reaction chamber is evacuated during /2 hour at 0.1 mm. mercury gauge. Under these conditions the heating is continued for further 2 hours. One obtains a viscous melt which solidifies to a completely clear p'lastic when cooling. The softening point is 195198 C.

Example 2 A mixture of 41.2 parts by weight of 4,4-dihydroxy- 3,5,3',5' tetra chloro diphenyl bis (,8 hydroxy ethylether) (melting point 203204 C.), 21.8 parts by weight of diphenylcarbonateand 0.0005 part by weight of lithium-hydride is melted under stirring while passing through purified nitrogen. The phenol split off is distilled off at 220 C. and 50 mm. mercury gauge. After 1 hour the pressure is slowly reduced to 0.5 mm. mercury gauge and the temperature raised to 270 C. After a further 1 /2 hours a high viscous melt is obtained which solidifies after cooling to a lightly yellowish clear plastic with a softening point of 225240 C.

Example 3 A mixture of 45.4 parts by weight of 2,2-(4,4'-dihydroxy 3,5,3,5 tetra chloro diphenylene) propane bis-(fl-hydroxyethyl ether) (melting point 117-118 C.), 22.0 parts by weight of diphenyl carbonate, and 0.002 part by weight of lithium hydride is melted under stirring and while passing through purified nitrogen. The bulk of the phenol split off is then distilled off at a temperature of 180200 C. and the pressure then reduced to 50 mm. mercury gauge within 1 hour. Within a further hour the pressure is slowly reduced to 0.3 mm. mercury gauge and the temperature increased to 250 C. and within a further hour to 270 C. while stirring. One obtains a viscous melt. After cooling the melt solidifies to a clear, transparent, almost colourless plastic with a K-value of 45.2, measured in a 0.5 percent methylene chloride solution at 20 C. The softening point is 170190 C. The product is soluble for instance in methylene chloride, chloroform, benzene and toluene. From sdlution for instance in methylene chloride or from the melt there may be produced films, fibres, and moulded articles. The mechanical properties of such articles may be increased by stretching.

Example 4 A mixture of 18.95 parts by weight of 2,2-(4,4-dihydroxy 3,5,3',5 tetra bromo diphenylene) propane bis-(fi-hydroxyethyl-ether) (melting point 104-105 C.), 22.13 parts by weight of 2,2-(4,4-dihydroxy-diphenylene)-propane-bis-(fl-hydroxyethylether) and 21.80 parts by weight of diphenyl carbonate is melted under stirring and while passing through purified nitrogen. The heating is continued at 50 mm. mercury gauge for /2 hour at 180 C. and for a further /2 hours at 200 C. while distilling off the phenol split off. During a further hour the pressure is reduced to 0.5 mm. mercury gauge and the temperature raised to 250 C. The heating is continued until a 'viscous melt is obtained. After cooling the viscous melt a plastic is obtained with the soften ing point of 160170 C.

Example 5 A mixture of 40.86 parts by weight of 2,2-(4,4-dihycyclohexane bis (B hydroxyethylether) (melting point 129--130 C.), 21.80 parts by weight of diphenyl carbonate and 0.001 part by weight of lithium hydride is polycondensed as described in Example 4. After cooling one obtains a thermoplastic material with the softening point of ISO-205 C. It may be worked up to films, fibres and moulded articles from the melt or from a solution.

Example 6 A mixture of 36.32 parts by weight of 2,2-(4,4'-dihydroxy 3,5,3,5 tetra-chloro diphenylene)-propanebis-(fi-hydroxyethylether), 6.32 parts by weight of 2,2- (4,4'-di-hydroxy-diphenylene) propane-bis (fi-hydroxyethylether), 21.80 parts by weight of diphenyl carbonate and 0.0005 part by weight of lithium hydride is polycondensed as described in Example 4. The so obtained plastic has a softening point of 160-180C.

Example 7 A mixture of 36.32 parts by weight of 2,2-(4,4-dihydroxy-3,5,3',5-tetra-chloro-diphenylene) propane-bis- (B-hydroxy-ethylether), 9.62 parts by weight of 2,2-(4,4- dihydroxy-3,5,3',5' tetra-chlorodiphenylene) propanebis-(,B-hydroxypropylether), 21.80 parts by weight of diphenyl carbonate and 0.0005 part by weight of lithium hydride is polycondensed as described in Example 4 to a plastic with a softening point of 148160C. It has a very good solubility and is suitable particularly for the production of lacquers and coatings.

Example 8 A mixture of 30.5 parts by weight of bis-ethylcarbonate of the 2,2-(4,4'-dihydroxy-3,5,3',5-tetra-chloro-diphenylene) -propane-bis-( ,B-hydroxyethylether), 22.7 parts by weight of 2,2-(4,4'-dihydroxy-3,5,3,5'-tetra-chlorodiphenylene)propane-bis-(,B-hydroxyethylether) a n d 0.001 part by weight of lithium hydride is melted under stirring and while passing through purified nitrogen. While heating for 2 hours the bulk of the ethanol split off is distilled off. Then the pressure is slowly reduced to 0.5 mm. mercury gauge and the temperature raised to 260C, and the heating is continued until a viscous melt is obtained. The properties of the resulting polycarbonate correspond to those of the product of Example 3.

We claim:

1. High molecular weight, fiber and film-forming thermoplastic, linear polycarbonates consisting essentially of recurring units of the formula wherein n is an integer from 2-3, and the Arsubdroxy 3,5,3',5' tetra chloro diphenylene) propane stituent represents the nucleus of a dihydroxy aromatic compound which is directly connected to the oxygen atoms through para linkages, Ar being selected from the group consisting of I X being selected from the group consisting of and R and R being selected from the group consisting of hydrogen, unbranched and branched monovalent aliphatic hydrocarbon radicals, monovalcnt araliphatic hydrocarbon radicals having up to 4 carbon atoms as sidechains, phenyl and furyl, Z representing the carbon and hydrogen atoms completing a cycle-aliphatic ring, and where said Ar substituent is substituted by 1-4 halogen atoms in the nucleus.

2. The polycarbonates of claim 1 wherein the halogen atoms are chlorine atoms.

3. The polycarbonates of claim 1 wherein the halogen atoms are bromine atoms.

4. The polycarbonates of claim 1 wherein Aris derived from a chlorinated dihydroxynaphthalene.

5. The polycarbonates of claim 1 wherein Ar is derived from a chlorinated 4,4-dihydroxy diphenyl.

6. The polycarbonates of claim 1 wherein Ar is derived from chlorinated 4,4-dihydroxy-diphenylene sulfone.

7. The polycarbonates of claim 1 wherein Aris derived from a chlorinated 4,4-dihydroxy-diphenylene alkane.

8. The polycarbonates of claim 1 wherein Ar is derived from a chlorinated 4,4-dihydroxy-diphenylene methane.

9. The polycarbonates of claim 1 wherein Aris derived from a chlorinated 2,2-(4,4-dihydroxy-diphenylene)-propane.

10. The polycarbonates of claim 1 wherein Aris derived from a chlorinated 4,4-dihydroxy-diphenylene oxide.

11. The polycarbonates of claim 1 where Ar is derived from a chlorinated 4,4-dihydroxy-diphenylene sulfide.

12. The polycarbonates of claim 1 wherein Ar is derived from a chlorinated hydroquinone.

Q L. 15. The polycarbonates of claim 1 wherein the recurring units correspond to the formula:

chlorine chlorine 16. The polycarbonates of claim 1 wherein the recurring units correspond to the formula:

chlorine chlorine 17. The polycarbonates of claim 1 wherein the recurring units correspond to the formula:

18. The polycarbonates of claim 1 wherein the recurring units correspond to the formula:

19. The polycarbonates of claim 1 wherein the recurring units correspond to the formula:

20. The polycarbonates of claim 1 wherein the recurring units correspond to the formula:

l CH3 Br Br 21. The polycarbonates of claim 1 wherein the recurring units correspond to the formula:

13. The polycarbonates of claim 1 wherein the recurring units correspond to the formula:

14. The polycarbonates of claim 1 wherein the recurring units correspond to the formula:

chlorine chlorine References Cited in the file of this patent UNITED STATES PATENTS 772,627 Great Britain Apr. 17, 1957 

1. HIGH MOLECULAR WEIGHT, FIBER AND FILM-FORMING THERMOPLASTIC, LINEAR POLYCARBONATES CONSISTING ESSENTIALLY OF RECURRING UNITS OF THE FORMULA 